trouble shooting and remedy of Dam Gates

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trouble shooting and remedy of Dam Gates

  1. 1. ONE DAY WORKSHOP ON DAM’S GATES ORGANIZED BY NARMADA, WATER RESOURCES, WATER SUPPLY & KALPSAR DEPARTMENT GANDHINAGAR SUPPORTED BY WALMI -ANANAD
  2. 2. SUB :- TROUBLE SHOOTING & REMEDIES IN GATES PAPER BY:- ER. C.C.PATEL Executive Engineer (Mech.) IRRIGATION MECH. DVN. NO-7, AHMEDABAD 02/28/11
  3. 3. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 1. Gate not lifting <ul><li>Power failure </li></ul><ul><li>Starter contacts or electric circuit faulty </li></ul><ul><li>Limit switch stuck </li></ul><ul><li>Power supply cable failure. </li></ul>Start standby generator check wiring, switches, fuse, starter contacts limit switches. Etc., check and rectify, do not oil limit switch . Check cable and cable joint systematically after disconnecting supply. Replace defective cable, fill cable compound in junction boxes. 5 Wire rope broken or loose from socket or clamp Check and rectify 6 Drive shaft Check Hoist couplings, shaft keys, gears etc. 7 Gate touching pier side Check pier, chip-off bulges on pier face. Check guide rollers.
  4. 4. Gate Touching with Pier Side Breaking of concreting Trunion
  5. 5. Arrangement of Line Shaft With Plummer Block & Flange Coupling Line Shaft Flange Coupling Plummer Block Stand
  6. 6. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 2. Motor getting hot 1. Defective power supply low voltage Check all 3 phases for voltage. 2. Over load Gate may be stuck and not free. 3. Moisture in winding. Check resistivity in winding, Dismantle, varnish and heat coils. 4. Clogged ventilation Check and clean the fan. <ul><li>Loose bearings </li></ul><ul><li>Solenoid brake of central drive unit not released when motor starts. </li></ul>Check and replace Check and adjust brake
  7. 7. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies Motor direction is changed Phase connection at the starter might have got interchanged Starter phase Contact might have got interchanged check. Phase connection at the starter might have got interchanged Starter phase Contact might have got interchanged check.
  8. 8. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 3. Gate travel not smooth 1. Uneven contact of side seals Check alignment and adjust seal. If embedded parts are not properly erected or seal not smooth, this may occur. 2. Drive shaft alignment or coupling defective. Check drive shaft for bends,slack coupling, keys, pedestal bolts. 3. Gears not meshing smoothly Check for defective gear profile, gear alignment, Plummer block loose. 4. Trunnion binding. Check for debris clean and grease Trunnion bearings. 5. Unequal wire ropes tension. Check wire rope in gate closed position -adjust Wire rope riding on the ridge of groove Check alignment of drum and gate lifting bracket Improper alignment of Trunnion axis Check and try to adjust by shims. This defect is difficult to eliminate.
  9. 9. Gear Not Matching Key Way
  10. 10. Gear Train Mechanism In E R Unit Pedestal Spur Gear Pinion Profile Of Gear
  11. 11. Trunion Cleaning & Oiling Debris Oiling Cap Trunion Arm Assembly
  12. 12. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 4. Wire rope Snaps. <ul><li>1.a) Wire rope strands broken or rusted/corroded. </li></ul><ul><li>Wire rope out of pulley groove </li></ul><ul><li>Broken Pulleys </li></ul><ul><li>Worn out bushing of pulley. </li></ul>Check and replace worn parts. 2. Wire rope length uneven Adjust turn buckle 3. Turn buckle threads worn Replace turn buckle by one of forged steel.
  13. 13. Wire Rope Out of Pulley Groove Wire Rope Pulley
  14. 14. Wire Rope Fixing With Clamp Wire Rope Clamp
  15. 15. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 4. Wire rope slipping from socket or clamp. Check wire rope clamp on Drum. Check socket, wedge wire rope clamps etc., and tighten. Ensure more than one idle winding of Rope on the drum in closed position of gate. 5. Motor does not stop at extremes of travel Adjust limit switches.
  16. 16. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 5. Hoist platform vibrating. 1. Lose bolts of deck plate or broken weld. Check and tighten or weld where possible. 2. Wire rope rubbing against hoist parts. Check and rectify alignment. 3. Wire rope not moving in the groove.on drum. Check alignment. 4. Gears not meshing properly Check alignment. Pedestal blocks keys, Grease open gears.
  17. 17. Wire Rope Rubbing With Hoist Parts Wire Rope Touch With Chequared Plate
  18. 18. D. H. Unit Alignment
  19. 19. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies Hoist platform vibrating. 5. Defective gear profile. If gears are not manufacture by ‘Hobbing’ accurate profile is not achieved and gears do not run smoothly. This manufacturing defect is difficult to rectify. 6. Hoist platform foundation bolts loose. Check and rectify. 7. Gate is vibrating. At small gate opening flow is unsteady. Change position.
  20. 20. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 6. Seals of side and bottom leaking. 1. Debris Check and remove 2. Worn out / damaged seals Check and replace during maintanence. 3. Missing SS seal travel plate. Sometimes, due to defective manufacture SS seal seat gets pealed off during operation. Rectify ,Find cause and set right.
  21. 21. Defective Wall Plate Joint S.S Cladding of wall plate Joint
  22. 22. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 6. Seals of side and bottom leaking. 4. Defective erection of embedded parts. Rectify after proper planning 5. Loose or broken clamp bolts. Check and rectify 6. Side sway of gate during travel Trunnion alignment to be checked.
  23. 23. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 7. Side sway of Gates 1. Guide rollers missing Check and replace 2. Trunnion alignment not correct. Check and adjust by shims to the extent possible. 3. Unequal length of wire rope. A new wire rope stretches under load. So replace both wire ropes or adjust turn buckle.
  24. 24. Setting Of Guide Roller in Gate Guide Roller Guide Roller
  25. 25. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 4. Shifting of yoke girder Check anchorage bolts nuts tie bars etc. 4. Shifting of yoke girder 5. Inaccurate alignment of embedded parts while erecting. Plan rectification ,consult expert. 5. Inaccurate alignment of embedded parts while erecting. 6. Excessive torsional twist of line shaft in the case of CDU located on pier. Check and use larger dia. shaft or hollow shaft. 6. Excessive torsional twist of line shaft in the case of CDU located on pier.
  26. 26. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 8. Structural failure of components or cracks. 1. Defective design Check design and reinforce. 2. Defective manufacture, excessive weld, stress concentration. Rectify and stress-relieve by heating peening etc. 3. Rust, wear and tear Clean and paint after rectification of defect. 4. Loose bolts uneven gas cutting of holes etc. Rectify.
  27. 27. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 9. Gate vibrating 1. Turbulent flow below the gate occurring at small openings. Do not keep gate open for long at opening less than 10% travel. 2. Imperfect anchorage. Check Trunnion, anchor bars nuts, tie bars etc., for looseness and rectify. 10. Hoist noisy while operating. <ul><li>Dry gears </li></ul><ul><li>No oil in reduction unit (Radicon) </li></ul>Rectify. Grease Check oil.
  28. 28. Radial Crest Gates problems , Causes and Remedy Defect Cause Remedies 11. Gate Creeps 1. Hoist brake not proper Adjust,brake shoe, Clean with petrol. Replace worn parts. Check spring.and solenoid. 2. Gear profile not accurate Stub spur gear accurately hobbed are self locking. 12. Manual operating device not working. 1. Clutch not engaging or slipping Check and rectify clutch linkages, Brake shoe 13. Dial reading not accurate Dial disc loose on shaft Drive chain loose . Tighten screw.Adjust drivechain,links ,Calibrate and correct Zero-error,
  29. 29. Arrangement of Magnetic Brake Magnetic Brake
  30. 30. Manual Operating Device
  31. 31. Arrangement of Dog Clutch Dog Clutch Jaw Handle
  32. 32. THANKS POWER POINT PRESENTATION PREPARED BY ER. K.B.TRIVEDI ER. R.C.RANA D.E.E.(MECH.) N.W.R.W.S.& Kalpsar Department, Gandhingar

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